Method for producing lightweight aggregates



3 Sheets-Shegt 1 Jail 5. DuBE INVENTOR.

:52 33 a mac:

J. B. DUBE METHOD FOR PRODUCING LIGHTWEIGHT AGGREGATES Filed Aug. 25. 1950 NR m 2313.3.

A TTORNEY May 19, 1953 J. B. DUBE METHOD FOR PRODUCING LIGHTWEIGHT AGGREGATES Filed Aug. 25, 1950 3 Sheets-Sheet 5 v I n. 1a

Jo/m B. 01/55 INVENTOR.

ATTORNEY Patented May 19, 1953 METHOD FOR PRODUCING LIGHTWEIGHT AGGREGATES John B. Dube, Dallas, Tex.

Application August 23, 1950, Serial N 0. 181,036

This invention relates to methods and means for producing lightweight aggregates and. more particularly to a method and means for producing lightweight aggregates by heating argillaceous, siliceous, volcanic or other materials.

This application is a continuation-in-part of my co-pending application Serial No. 787,347, filed November 21, 1947, and which has matured into Patent No. 2,449,787, dated April 24, 1951,

Lightweight non-metallic aggregates offer great advantages over ordinary sand and gravel when employed in making concretes, mortars, building blocks, shapes, forms and bricks as well as in many industrial applications because of their unusual lightness and strength, practical inertness to acids, their good insulating, fire resistant and absorbing properties, and their imperviousness to termite or other insect attacks. It is desirable, therefore, that a method and means be provided which will efiiciently process argillaceous, siliceous, volcanic material to form lightweight aggregates. The lightweight aggregates formed by the expansion of the treated material are in the form Of granules which are vesicular in structure having many voids, some of which extend to the outer surfaces of the granules. It is desirable to seal the voids or openings communicating with the surface of the granules in order to lessen the absorption of water by the granules of the lightweight aggregate. Sealing of the voids of granules of lightweight aggregates leads to the following advantages:

The absorption of water by the lightweight aggregate from the mix in the formation of concretes is decreased, the mix therefore requiring much less water;

The slump of the concrete mix made with the aggregate is decreased;

The degree of expansion and contraction of the set concrete made with the aggregate is decreased;

The weight of the set concrete made with the Claims. (Cl. 252-378) The concrete mix is made more workable since the cement employed in the mix is permitted to spread quickly and to come into closer contact with the whole surfaces of the granules and the formation of dry spots in the mix is rendered less likely since the absorption of water by the voids in the granules is prevented.

Accordingly, it is an object of my invention to provide a new and improved method and means for producing lightweight aggregates.

It is another object of my invention to provide a new and improved methodv and means for producing lightweight aggregates by heating argillaceous, siliceous, volcanic or other materials.

It is another object of my invention to provide a new and improved means forv producing lightweight aggregates formed of granules of vesicular structure whose voids or openings are sealed. 4

It is another objectof. my invention .to provide a new and improved method and means for continuous processing of materials to produce lightweight aggregates.

It is another object of myinvention to provide a new and improved rotary kiln.

It is still another object of my invention to provide a new and improved kiln for heating materials to produce aggregates formed of vesicular granules, to dust thegranules with a cementitious 'material while the granules are at their greatest degree of expansion, and to spray the dusted granules with water or steam to set or harden the cementitious material sealing the voids.

Briefly stated, my new and improved means for producing lightweightaggregates comprises an inclined cylindrical shell mounted for rotary movement about its central, axis. The interior of the shell is provided with a plurality of helical risers which serve to cascade the treated mate rial during its passage from the upper intake end'of the shell to the lower discharge end of the shell. The upper section of the shell is lined with heat insulating material which is immediately adjacent a section of the shell which is provided with screens through which fine materials may discharge from the shell. Intermediate the intake end of the shell and the screened section is disposed a flame gun which heats the treated material to a temperature which is intermediate the incipient and complete vitrification temperatures of the treated material. The heat completely dehydratesthe mass and drives out all gases of constitution, thereby forming myriad voids in the granules of the mass. Positioned between the flame gun and the screen section of the shell is a dust blower while immediately below the screened section is positioned a water sprayer. Pipes are positioned within the shell to provide gas and oxygen or air to the flame gun, dust or powder to blower and water to the spray, said pipes being stationarily mounted in the rotatable shell.

The new and improved method of treating raw material to produce lightweight aggregates comprises heating the raw material to a temperature intermediate the incipient and complete vitrification temperatures of the material to form vesicular granules, blowing a dust of cementitious material on the vesicular materials, spraying the dusted granules with water or steam, and continuously cascading the materia throughout the above steps of treatment.

For a better understanding of my invention reference may be had to the following description taken in connection with the accompanyin drawing and its c pe will be pointed out in the appended claims.

Figure l is a side elevational view of my new and improved ro ary kiln;

Figure 2 is a cross-sectional view of the rot ry kiln showing some of its associated structures;

Figure 3 is a cross-sectional view taken along line 3-3 of Figure 2 Figure 4 is a cross-sectional view taken along line 4-4 of Figure 2;

Figure 5 is a cross-sectional view taken along line 5-5 of Figure 2;

Figure 6 is a cross-sectional view taken along line 6-6 of Figure 2;

Figure .7 is a sectional view of one of the jets .of the flame gun;

Figure 8 is a sectional view taken along line 8.-.-,B .of Figure 7;

Figure 9 is a fragmentary sectiona vi w taken along line ,9--9 of Figure .4; and

Figure 10 is a fragmentary sectional view of the kiln showing an abrasion shield at the terminus of the insulated section of th kiln.

Referring now to the drawing, the rotary kiln In of my invention comprises a cylindrical shell I] which is supported in an elevated inclined position on stands I2 and 13 which may be of concrete. Outer bearing cases 14 and I5 are secured to stands I2 and 1.3, respectively by means of bolts I5 while inner bearing cases I! and I8 are rigidly secured to shell II adjacent its upper and lower ends respectively. A plurality of roller bearings I9 and 2.0 ar secured between inner and outer cases 14 and 1.1, and I 5 and I8, respectively. and rotatably su port shell II on stands I2 and I3. A ring gear 2I is rigidly se cured about shell ll intermediate its end and is in mesh with a pinion gear 2.2 driven by a motor 2311 which is mounted on a stand 24. Motor 2301. imparts rotary movement to shell I-I through gears 2I and 22.

A plurality of riser plates 23 are secured to the inner surface of shell II by means of lugs 24. Lugs 24 may be rigidly secured to shell I I by welding as may be secured riser plates 23 to lugs 24. Riser plates 23 extend longitudinally through shell II in a spiral or helical fashion, ar paral- 181 to each other, and extend inwardly from the inner wall surfaces of shell I I.

In order to prevent the wearing away of the refractory and insulating lin r of th kiln by passage of the ma erial oil the end thereof, an annular shield 24:! embraces he t minus of. the liner (Fig. 10)

The upper portion of shell II comprising the sectionsA, B, C and D is insulated to prevent the passage of heat to the outside of shell II. The insulation comprises a layer 25 of plastic insulating material which is rammed into place against the inner surface of shell I I between riser plates 23. A second layer 26 of refractory and insulating material is disposedon layer 24 between riscr plates 23 and is in turn covered by a relatively thin layer 2! of graphite which is employed to prevent rapid wear of the refractory material 2.6 due to the abrasive action of the material passing through shell I I.

Portions of shell II between riser plates 23 are removed and the openings are covered by screens 28 which may be secured to shell I I by welding or in any other conventional manner. The screen section F of shell II provided with screens 28 is enclosed by a housing 29 having a discharge spout 3!!- Housing 29 and spout 34 may be supported by a stand 3!. shell II being rotatable in housing 29- The s ctions E. F nd G f h ll I! are devoid ciany insulation.

A plurality of brace rings 32 are disposed in longitudinally spaced relationship in shell I I and are secured to she l II by m ans f ra es 33 which are secured to shell II and brace rings'32 by welding or other conventional means. Disposed within, and supported by, brace rings 32 are stationary disks .34 which are apertured to receive and support water or steam conduit 35, dust conduit 36, fuel conduit 31, and oxygen or air conduit 38.

Water or steam conduit 35 extends between a water pump 39 and. a Water or steam sprayer 40 disposed in section F of shell-II. Dust conduit 36 extends between a dust blower 4|, supplied with dust material from bin 42, and a dust sprayer 43 disposed in section D. Fuel conduit 31 may conduct a fuel in the form of gas or a gas pressure booster or pump 44 and a flame gun 45 dise posed in section C of shell II. Oxygen or air conduit 38 may be connected to any suitable source of oxygen .or air under pressure to supply oxygen to flame sun 45.

Water sprayer 40 comprises a transverse conduit .46 secured to and communicating with water conduit 35 and a pair of longitudinally extending conduits 4! and 48 connected with transverse conduit 45. Conduits-4'! and 4.8 are provided with a plurality of spray heads 49. Two or more water Sprayers 40 may be connected to water conduit 35.

Dust sprayer 4| comprises an arcuated conduit 50 secured to and communicating with dust conduit 35 and three longitudinally extending conduits SI, 52 and 53 connected to arcuated conduit 50. A plurality of spray heads 54 are connected to each of he c nduit 5|, 52 and Two or more dust Sprayers 4| may be connected o du conduit .36-

Flame gun 45 comprises an arcuated transverscly extending conduit 55 secured to and communicating with fuel conduit 3'! and a plurality of longitudinally extending conduits 56 connected to arcuated conduit 55. Each of the conduits 56 is provided with a plurality of jets 5?, each having a member 51a provided with a threaded upper end 58 which engages in a suitably threaded opening in its associated conduit 55. The fuel, i. e gas, flows from each conduit 55 through narrow aperture 5.8 in each member 57a to an e l rged mixin chamber 59. A plurality of upper apertures 60 also communicate with mixing chamber 59. Air or oxygen is drawn in through apertures fill when gas flows through aperture 58'. The. lower end of member Ela'is reduced tov form a sleeve 6|. A barrel 62 is secured to member 51a by means of a flange 63 which engages in a suitable annular groove in member 51a. The barrel 62 is provided with a plurality of apertures 64 through which air or oxygen is drawn to mix with the mixture of gas and air or oxygen flowing from mixing cham ber 59.

In operation, the material to be treated such as crushed shale, clay, vermiculite or'other material is lifted by a conveyor into a bin 86 provided with a spout 61. Spout 6'! extends into the upper end of shell H and the raw material is controlled as it passes into Section A of shell I I. Shell II is rotated continuously by motor 23a so that riser plates23 each continuously lifts the raw material deposited in section A and then allows it to cascade down to'the bottom of section A of shell II. The raw material moves toward section B since shell I l is inclined down- Wardly from section A. As the raw material travels through section A, the heat produced by flame gun 45 and not completely utilized in sections C and B passesv through section A and drives off the surface moisture on the granules of crushed raw material. At the same time it begins to heat the raw material and raise the temperature. I

As the raw material moves further down the shell H to section B, it is heated still more and moisture of constitution within the granules of raw material is driven off. At the same time the temperature of the raw material is continually raised as it approaches section C. Just before the raw material enters section C, its temperature is raised by the heat absorbed by the raw material to the point where the raw material approaches the explosive, expansive or plastic stage. Gasses forming within the granules of the heated raw material will expand the granules due to the pyro-chemical reaction generated by the radiant energy of the flame.

With the rotating kiln or cylinder set at a predetermined angle of repose on the piers, the risers 23 by virtue of their helical course throughout the kiln, cascade the material and accelerate the travel of the mass throughout the length of the kiln. Depending upon the angle at which the risers 23 are set, and the space between the said risers the material being processed will, first, be cascaded at an angle in the direction inwhich the mass is travelling, thus materially increasing the speed of the mass coursing down the kiln to the discharge end.

Second, the space between the risers 23 will determine the number of times the entire mass in the kiln will be exposed to the pyro-chemical reaction of radiant energy. These exposures can be two, three or four times per minute, should the revolution of the kilnbe one per minute. Should the speed of revolution be increased the speed of the mass travel will likewise b e ihcreased and thereby adding to production.

Third, the cascading action of the mass with its many exposures to the radiant energy causes a positively uniform finished product. To the present day, the production ofa uniform product is almost impossible due to the travel of the 6 of the .kiln, and thereby causes damage due to abrasion.

Fifth, the use of risers 23 further eliminates the formation of a ring in the hot Zone of the kiln. These rings are formed by the sliding down of the plastic mass on the refractories. Due to the soft plastic condition of the mass, the sliding down of the heavy mass causes a portion of the plastic material to adhere to the ring formed on the refractories of the hot zone. To clear these rings, stoppages of work are necessary thereby causing muchtime lost and greatly added expense to production.

With the increase of production and auniform product with the saving of gas and electricity, the profits of operation will be unques tionably in favor of my new unit of fabrication of lightweight aggregates. I

When the preheated material ent'ersinto section C, it cascades directly into the radiant energy created by flame produced by flame gun 45. Jets 51 areso arranged that the flame Droduced by each jet 5! blends with the flames produced by its immediately adjoining jets 5] to produce a wall of flame through which the preheated material cascading off riser plates 23 must travel. The radiant energy developed by the flame is blasted against the granular material and such radiant energy that does not come into contact with the granules of the, mass rebounds from. the refractory lining of the shell and is carried towards the feed end of the kiln to preheat the cascaded material entering the kiln. It will be noted that arcuated conduit 55 is concentric with the curvature of shell II and extends upwardly in the direction of rotation of shell ll so that the preheated material must travel through the wall of flame as it cascades downwardly. As the preheated material travels through the flame, its temperature is raised suddenly to make intermediate its incipient'and complete vitrification temperatures and a pyrochemical reaction takes place in the granules which greatly expands the volume of each granule. Gases formed in the granules during this pyro-chemical reaction seek an outlet and greatly expand the volume of the'now plastic granules and cause the granules to have a vesicular structure, some of the gas pockets communicating with the outer surfaces of the granules. As has been implied, not all of the heat generated bythe flame gun 45 is absorbed by the material passing through section C of shell I I.

The expanded granules pass from section 0 to section D where a cementitious dust is blown on the expanded granules by dust sprayers 43.

mass down the kiln without the use of risers.

Fourth, the use of risers 23 completely eliminates the rising action of the mass to the angle of repose in the kiln and then suddenly causes the mass .to slide ,down on the refractory lining The cementitious dust seals the voids or openings in the expanded granules when the voids are at their greatest degree of expansion so that when the granules contract these will be provided a solidified surface seal. Conduits 50 of sprayers 43 are so positioned that the dust is blown on the expanded granules as they cascade off riser plates 23.

The expanded granules then pass into section E where the very fine granules and the excess dust drops through the screens 28 into the bottom of housing 29 and fall through spout 30 into a hopper 68 positioned below spout 30.

The larger granules which do not fall through screens 28 pass into section F in which arelocated water or steam sprayers 40. The water or steam sprayers are so positioned that the expanded granules are exposed tov a very fine'water or steam spray as they cascade ofi riser plates 23. The water or steam spraysets 01" hardene the. eementitious. duet which has. been. pos t the voids of. he xpanded g anules. se tio Dr Sc eens 28. are em loyed. bei e he wa r prayin oi theexpanded and dusted, g an les. in rder to. preventv the. a glomer tion of. r l w ich uld t ke pla e due. o th b nding a tien of, the. xc ssdust. if it. ere pr y sprayed. h, water.

The expand d granules. begin to cool as soon the ass. ine et en D- and ontinue. to. 0.0.01. a y Pass throug sectio s If and Sec ions E. F and G hav not. e n provided with nsula ns: material n rder. at e t may be rans ierreci t m h expanded ranules. to the atrxios-- p ere thro gh the. metal sh l H y onduction- In section G, therefore, the. expanded granules are further cooled. before passing. out. of. shell H.

It will be no e that throughout i s pa sa e hr u h shell LL. h tr a ed at ria as bee continuou y asca ed. by the act on of ser plates. 23-- Tnis caecaeina acti n nsur s. at al granules. be exposed; to the heat n. he reheatin sections A; and, B. to. e flam n sect on C and to the us and th eror steam. i sections D and E, The cooling oil process in sections D, E, E- and; G and. the: screening process in section E. is also f cili ated. e; h ca ca in action The: speecl at, which the, treated material travels tlnouehfs e l i depends n. the sp ed of otation of shell H. anal thenumber, spacing. and, twist of riser plates 23. It can be. seen. that by varying any: one if the-above iactors. the speed or travel or the, treated material may becontrolled.

Shell U is made at a. heat resistant material. Rise p a es. as and. flam gu .5 are made awe. ally hig ly h t insis nt. mater nc they are; raised to. very: high temperatures. The temperature to, which the treated; material must be heated; to obtain the desired expansion of the granules varies with theof raw material em ,loyed. The-temperature can be. controlled by c. r in th aareunt fuel, g s supp i d to fl megun. 5..

After passing thr ugh he l. H, the panded ranules. re r e e a c u e scr en E ih l rger ranules cannot. pass hrough screen so amt therefore descendon. a. chute 7-0, to a. bini. Th granules that dro hrou scr en 69 a l o screen positio ed elo r en ea. Medium ic ir granu es ea -nctpass t r u h scr en and descend on a, chute 13K to, a, bin Hi. The line granules: ac t an 1' mai ipa duet allthrou h creen l2 i o a bin; 1 S eens 6.8. and m and bins fill, H, M and 15 are supported above the roun b n ention l etude Qr. supp t so hat. the expanded ran les. may be delivered directly from the bins. into trucks or other trans- Pett ng: mea e- W, 1e i have descr ed and llustrat a e i' red mzte me t are. xample f. n tion. it. vt l he; Ola -m s, that. chan es a d mod fication can be made Without departing from my invention an i 3.. here e-a m t e append d lai to. co er l; su h hang s and med fi t a fall: within the true spirit,- and scope or my invention.

What is, claimed is: 1

1. The. method oftreatinga. granular ma er to form lightweight aggregates. composed or discrete sulcrstantial ly non-agglomerated; granules ompr s n at ng th ranular material: t a temperature in erm ate the. ineinent' anal com.- plete vitrification temperatures: of. the mate a to cause expansion of the granules, sealing the surface voids n he molten expa ded aranule wi h. cementitieus materiaL and trea ing t e xpan letl granul s. with Wa er r et. h cementiti iis. ma e ial seal t o s the ramil e- T e method Qi treat ng. a gran lar ma e a to form. lightweight. ag re a s compo d f di rete. ubstan ially ien-ag omerated, gran e comprising heating the granular material to a temperature intermediate the incipient and comp et vitrification temperatures of the material to caus e pansion. of the ranu es, s al t surf ce, voids in h e anded m lte ra ules th cementitious. material, treating. e panded granules. ith water or steam. o. set. h ementitious material sealing he voids of e ranule nd ascadi g h ranulated ma ri ur thev above st ps of reatmenthe. method of tr atin a. ran lar mater al o or l g twei ht ag re ates compo ed of diser sub tant al y non-a gl rat d ranul s comprisi g h atin the gran lar ma erial to a temperatur intermediate the cipi n nd. com.- plete vitrification temperatures. of the material to cause expa sion of. he ranules ng. a fin e ntitious us on. the exp nde anul in plastic. form. to seal the surface, openings in th expanded granules, and treatin h ex: panded and dusted granules with water or steam to set. the cementitious material sealin the surface open ngs- 4. The. method of treating a granular material to form lightweight aggregates composed of dis,- e e e substantially non-a lomerated granules comprising heating the granular material to a temperature intermediate. the incipient. and coinlete, vitrification temperatures of. the. material to cause expansion of the granules, blowing a fine, cementitious. dust. on the plastic. molten gran ules t S al. the. surface, openings in the. expanded granules, treating the expanded and dusted granules. with water or steam to set. the cementitious material sealing the. surface openings, and cascacling the granulated material during the above steps. of treatment.

5. The. method of treating a granular material to; form lightweight aggregates composed of discrete v substantially non-agglomerated granules comprising heating the. granular material to a temperature intermediate. the, incipient and complete vitrification. temperatures of the material to. cause. expansion of the granules, blowing a line cementitious dust. on the molten granules to. seal the surface openings, in the expanded granules, and treating the expanded and dusted granules with a, fine, spray of water or steam to set the cem miitious. material sealing the surface open ngs.

6. The method of. treating a granular material toform lightweight aggregates composed of dis.- erete ubstanti l y non a elomerated ra ules comprising heating the granular material to. a temperature intermediate. the incipient and complete vitrification temperatures of the ma.- terial tov cause expansion of the granules, blowing a. fine cementitious dust. on. the. plastic, molten granules to: seal the surface. openin s in the expend d r n l s, and cascading the granulated material during the above. steps of treatment.

7. The method of, treating a granular material to formlightweight; aggregates composed of diset ea tan iallr non-a glomer ted. ranules cementing, h ating; t e.v g anu ar aterial. to a. temp ature nterme i e the. incipient and complete vitrification temperatures of the material to cause expansion of the granules, blowing afine cementitious dust on the molten granules to seal the surface openings in the expanded granules, screening the expanded and dusted granules to remove excess dust, and treating the screened granules with water to set the cementitious material screening the openings.

8. The method of treating a granular material to form lightweight aggregates composed of discrete substantially non-agglomerated granules comprising heating the granular material to a temperature intermediate the incipient and complete vitrification temperatures of the material to causes expansion of the granules, blowing a fine cementitious dust on the molten granules to seal the surface openings in the expanded granules, screening the expanded granules to remove excess dust, treating the screened granules with steam to set the dust material sealing the openings, and cascading the material during the above steps of treatment.

9; The method of treating a granular material to. form lightweight aggregates composed of discrete substantially non-agglomerated granules comprising heating the granular material to a temperature intermediate the incipient and complete vitrification temperatures of the material to cause expansion of the granules, blowing a fine cementitious dust on the molten granules to seal the surface openings in the expanded granules, screening the expanded and dusted granules to remove excess dust, and treating the expanded and dusted granules with a fine spray of water or steam to set the dust material sealing the surface openings.

10. The method of treating a granular material to form lightweight aggregates composed of discrete substantially non-agglomerated granules comprising heating the granular material to a temperature intermediate the incipient and complete vitrification temperatures of the material to cause expansion of the granules, blowing a fine cementitious dust on the expanded granules to seal the surface openings in the expanded granules, screening the expanded and dusted granules to remove excess dust, treating the expanded and dusted granules with a fine spray of water to set the cementitious material sealing the surface openings, and cascading the granulated material during the above steps of treatment.

JOHN B. DU'BE.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 1,041,565 Arthur Oct. 15, 1912 1,885,845 Lindhard Nov. 1, 1932 2,187,538 Butler Jan. 16, 1940 2,314,836 Seil Mar. 23, 1942 2,501,962 Pierce Mar. 28, 1950 2,517,235 Pierce Aug. 1, 1950 OTHER REFERENCES Seeley: W., Mudd Series, pub. by Amer. Inst. Min. 8: Met. Eng, N. Y., 1937, pg. 54, copy in 252-378P. 

1. THE METHOD OF TREATING A GRANULAR MATERIAL TO FORM LIGHTWEIGHT AGGREGATES COMPOSED OF DISCRETE SUBSTANTIALLY NON-AGGLOMERATED GRANULES COMPRISING HEATING THE GRANULAR MATERIAL TO A TEMPERATURE INTERMEDIATE THE INCIPENT AND COMPLETE VITRIFICATION TEMPERATURES OF THE MATERIAL TO CAUSE EXPANSION OF THE GRANULES, SEALING THE SURFACE VOIDS IN THE MOLTEN EXPANDED GRANULES WITH CEMENTITIOUS MATERIAL, AND TREATING THE EXPANDED GRANULES WITH WATER OR STEAM TO SET THE CEMENTITIOUS MATERIAL SEALING THE VOIDS OF THE GRANULES. 